Case Studies
The following are different case studies to highlight some particular repairs that have been carried out using the Window Care System.
You may find it useful to compare them to your own repair jobs. Mouse over the thumbnail pictures for a closer look.
This door 
was
considered beyond repair, the bottom rail had serious penetrating decay, the back putties were perished and leaking and the joints were open. The
details of the door were non-standard, meaning that a purpose made or "special"
replacement would be called for and the glazed panels were of laminated safety
glass which added to the expense not to mention time involved. The
new door called for by the specification would have cost £313 in June
1995 when the work was carried out. We were sure that
not only could the door be saved it could also have a new lease of life which
would ensure that it lasted longer than a new door! The following photographs
show just how we were able to bring this about and what it cost.
When the door was
removed we found that the decay
extended all along the bottom rail 
and into
both mortice joints 
where it had penetrated to the inside face under a kicker
plate. Incidentally the problem had been caused by moisture having access
to the concrete threshold and in effect filling the gap between the concrete
and the bottom rail and penetrating the timber via the end grain of the stiles
and the open joint of the bottom rail.
This picture 
shows
a typical open joint between the middle rail and the style, almost always
a feature of this type of glazed door. The horizontal shake present in the
middle rail is also a popular fault leading to moisture ingress and wood
decay. Open joints
and split timbers are usually one of the first places where paint breakdown
starts.
This door 
opens out and therefore the top joints were also vulnerable
to problems adding to the instability of the timber.
It was decided that
the best plan of action would be to remove about half of the bottom rail 
and renew it using the Window Care standard resin and timber method to effect
a permanent repair. A jig saw was used to cut through the rail but still
leaving a small area of decay in both stiles. This was removed
using a Window Care Profi, a specially designed tool for removing wood decay
without damaging the sound timber.
It is important to remove all decay and
any soft or weakened timber during this process. 
The sound
timber should be checked for moisture level using our Wood Condition Meter 
and a level below 18% is necessary for the best quality repairs. The decorative
finish should be removed to at least 10mm beyond the repair to ensure that
the repair compound
is in full contact with the timber at the edges of the repair. It can be
seen from this photograph that good, clean and sound timber 
has been exposed
and this is what should be looked for on a good quality repair.
The next stage
was to apply Dry Fix primer to both contact surfaces 
and leave it to penetrate
for about 30 minutes, (longer is fine, but bond with Dry Flex within the
same day). Dry Flex was "buttered" on to the receiving timber ensuring
that enough thickness was applied to give a minimum bed of
5mm. The new timber
was offered up and pressed into position and lined up to match the existing
profile and the excess Dry Flex removed with a spatula and used elsewhere.
In this case two locating screws were used as the door was re-hung on the
same day (normally no fixings would be necessary on timber and resin repairs).
Once the new timber was in position 
the remaining area of the repair was
completed with Dry
Flex. 
This material is particularly well suited to timber and resin repairs
as it combines flexibility with very high bond strength. The two timbers
can move independently but the joint will remain sound. This method of repair
is very successful on cill fronts where the repaired two timbers will act
as the original one-piece cill and the procedure is exactly the same as described
here.
Once the major decay repairs are carried out attention must be paid to what we
call conservation works which in this case included open joints and
back putties. 
If the door is to have a long term future it is essential to
seal the open joints and the bottom putty line. We can see the Profi cutter
in operation 
opening up the joints and shakes to the middle rail using
the straight cutter which provides a slot 5mm wide and 10mm deep. The same
operation is being carried out to the top joints which sometimes need treatment
in an outward opening door. From this point onwards sealing the joint is
a small Dry Flex repair 
and as before it is essential to expose sound
clean timber and
check for moisture levels below 18%. The flexibility, strength and water
sealing properties of the Dry Flex will ensure that the joint ceases to
be a source of moisture ingress. This was a typical conservation joint on
a two panelled door which was very obviously open before the conservation
works were carried out. Once the Dry Flex repairs have been completed it
is usually 24 hours before final finishing is carried out and this
involves smoothing off with woodworking tools and light sanding prior to
decorative finishes being applied. Dry Flex is temperature sensitive and
a longer cure will be required in colder weather.
To remove back
putties we used the Profi Assist which is an attachment which enables the
operator to remove the back putty without breaking the glass and cuts a slot
adjacent to the glass approximately 4mm wide and 8mm deep. This operation
was carried out to the bottom putties and up to 300mm to the adjacent vertical
putty. After careful
removal of any dust or debris the gap was filled with Dry Seal Elastic Glazing
Sealant 
by being pumped in using a heavy duty mastic gun via the supplied
nozzle cut to deliver the correct amount to the prepared groove. The Dry
Seal was then smoothed to a water shedding profile using a Dry Seal Applicator
and allowed to cure for 48 hours after which the decorative finish could
have been applied.
This door was
rescued 
from wasteful disposal at a mere cost of £78, under 25% of
replacement cost! The repair and conservation works took less than 4 hours
to complete in total and this door is still looking good and in better condition
than near-by original doors and new doors which did not have the benefit
of The Window Care System.
Jessamine Cottage Entrance Column
After many years of bad weather plus general wear and tear this much-loved wooden column 
looked beyond repair and would've cost hundreds of pounds to replace, so it was decided that a repair would be attempted. 
Firstly, the rotten timber (which was plenty) was carefully removed using a round cutter on a mini profi 
and brought back to sound timber, this obviously left a gaping hole in the middle of the structure and as well as being unstable, the remaining timber looked terrible as it was.
The next step was to prepare for the application of the dry fix primer/stabiliser and subsequently the dry flex resin.
As the centre of the column was now fairly hollow and the area to be repaired was so vast, a timber splice repair 
was by far the most cost-effective option, so sections of timber were added to the centre of the gap and wedged appropriately into position. The surrounding area was treated with Dry Fix Primer/Stabililser, including any facing splices that may meet the resin upon application.
The resin was applied directly to the structure and shaped as per the original design, 
then worked into all remaining gaps to make a solid, watertight seal.
When fully cured and dried, the column was carefully planed and sanded to a smooth, paintable finish ready to be decorated.
The finished job was visually fantastic and very cost-effective too. Another fine example of what the Window Care System can achieve with minimal time, effort and financial outlay.
Saving a Victorian Bay Window on a grade II Listed building
This bay window had serious decay in both cills and boxframe and replacement was an option soon abandoned because of cost and disruption. 
The clients surveyor knew our system well and had faith in our repair and conservation methods. The result? 
Well repaired and it's long term future assured at a fraction of the replacement cost. Our system is well suited to buildings of architectural and historical interest primarily because the repairer needs only disturb the decayed element of the frame leaving the sound timber intact .
Correctly carried 
out repairs are not apparent.
This is just one example of a strong and durable repair which can bring back to life severely damaged joinery and restore the quality of a fine building. 
The Window Care System is equally effective on modern joinery which is even more susceptible to attack by wood decay.
Typical 1930's Bay Window in a semi-detatched house
This typical semi-detached house built in 1935 was suffering from the usual problems associated with this era of window. 
The oak cills had decayed around the mitre joints 
which were open to moisture ingress and the handrail bolts holding the cills together had rusted and caused
splits along the grain opening up the timber to even more moisture. 
The effect was to cause serious decay in the outer section of the oak to a point generally in line with the mullions and softwood lights. 
The softwood fixed and opening lights were affected by decay emanating from moisture ingress via open joints and linseed oil putty failure. Two of the bottom rails were completely decayed.
Most of the mullions had decayed at the junction with the cill encouraged by excess movement and open joints.
***MOST SURVEYORS WOULD CONSIDER THIS BAY WINDOW TO BE BEYOND REPAIR***
BUT NOT IF THEY WERE FAMILIAR WITH OUR METHODS AND PRODUCTS! THIS BAY AND ALL THE OTHER WINDOWS ON THE HOUSE WERE SUCCESSFULLY REPAIRED USING THE WINDOW CARE SYSTEM AT A FRACTION OF THE COST OF REPLACEMENT AND (JUST AS IMPORTANT) LEFT LOOKING AS IT WAS WHEN BUILT ALL THOSE YEARS AGO.
HERE'S HOW IT WAS DONE
The paint was removed from the areas affected by decay to at least 10mm beyond the decay.
All decayed areas of the oak cill were removed back to sound timber using a woodworking chisel. All decayed areas of the mullions and bottom rails were cut back with the Window Care Profi to sound timber using the round cutter. Changing to the straight cutter the open joints not affected by decay were opened to a depth of 10mm and a width of 4mm in readiness for forming conservation joints. Dry Pin in-situ preservation capsules were inserted at the ends of the cill adjacent to the 
brickwork and in the end frame adjacent to the brickwork and just above cill level. The sound timber was checked for moisture content using the Wood Condition Meter, no light = well below 14% (good adhesion), green light = around 14% (good adhesion), amber light = around 18% (borderline) and red light = too wet to achieve good adhesion (stop and allow to dry). The areas to be repaired were lightly sanded to remove any loose fibres left proud by the cutting out and the whole given a coat of Dry Fix Primer which was left to penetrate for at least 30 minutes. 
Dry Fix was also applied to the contact surfaces of all new timbers i.e. backs and ends of new cill sections, ends of new bottom rails.
These surfaces had been left rough sawn for the best adhesion. Dry Flex RP, the main repair compound, was dispensed using the Dosing Pistol on to the Mixing Plate and mixed using the Application Knives. When the colour change denoting a correct mix had been achieved 
the Dry Flex was "buttered" on to the contact surface of the new cill section whilst the Dry Fix was still tacky (any time the same day) and the new section pressed into position squeezing out the surplus material but ensuring that at least a 4mm bed was left between the new and old timbers. Each new section of cill was fitted in a similar manner in a continuous operation also maintaining a 4mm bed on the mitred joints. No fixings were required or used. The new bottom rails were fitted in a similar manner with straight 4mm joints without fixings and the new joint will prove stronger than a mortice and tenon.
The resin-only repairs followed and the Dry Flex RP was pressed into position using the application knives and needed no means of retention as it is slump free and can be applied in one application 
to any height and any depth to effect a high strength, flexible repair.
After curing (about 24 hours in summer) the repairs were finished 
using woodworking tools followed by light sanding and left ready for decoration.
No glass was broken or removed during the repairs even where bottom rails were replaced which is quite usual for a Window Care project. Last but by no means least the bottom glazing line was dealt with because, as you may recall, the linseed oil based putties had perished 
and were responsible for much of the deterioration found on the frames. The remnants of the bottom putties were removed and at least 50mm to the adjacent verticals (to ensure a good seal at the corner) and the timber rebates were cleaned off and given one coat of paint primer to seal the surface.
The glass in the rebate area was thoroughly cleaned to ensure good adhesion and Dry Seal Elastic Glazing Sealant was applied to the rebate and screeded to shape using the Dry Seal Applicator. 
After 48 hours the Dry Seal was ready for decoration using the same paints as for the rest of the frame.
A Job well done! 
WHAT WE HAVE ACHIEVED
- The Windows Have Been Saved -
- The House Looks Better For It - Replacement Windows Just Never Look As Good.
- It Has Saved A Lot Of Money.
- The Occupier Had No Disruption.
- The Future Decoration Cycle Will Be Extended.
- Environmentally Friendly.. No Waste Of Natural Resources.
- No Builders Skips Ending In A Landfill Site.
- No Greenhouse Gases Produced In Manufacturing New Frames And Glass
- They Now Have A Long Term Future!
Feel free to contact us to discuss anything at all about Window Care Systems Anglia
Please visit www.countyconchem.co.uk to see what our sister company can do for you!
- Helpful to the environment, save raw material!
- Easy to use, multiple uses!
- Full, technical support and after sales care!
- Complete repair system from start to finish!
A cost effective solution to an age old problem!
See for yourself!
Compare the cost of repair to the cost of replacement!
